Base coats and methods of producing the same

ABSTRACT

Base coats and methods of producing the same are provided. In an exemplary embodiment, a method of producing a base coat includes forming a CPO intermediate and a color intermediate. The CPO intermediate includes a CPO solvent and a chlorinated polyolefin, where the chlorinated polyolefin is present in the CPO intermediate at from about 5 to about 20 weight percent, based on a total weight of the CPO intermediate. The color intermediate includes a color imparting additive and a color solvent that is different than the CPO solvent. The CPO intermediate and the color intermediate are combined to form the base coat.

This application is a continuation-in-part of U.S. application Ser. No.16/117,501, filed Aug. 30, 2018, the contents of which are incorporatedherein by reference.

TECHNICAL FIELD

The present disclosure generally relates to base coats and methods ofusing and producing the same, and more particularly relates to basecoats that can be directly applied to polymeric substrates without aprimer layer, and methods of using and producing the same.

BACKGROUND

Manufacturers typically paint motor vehicles during the manufacturingprocess, where some of the motor vehicle components primarily includethermoplastic polyolefins, polypropylene, or other polymers. Forexample, many bumper components of modern motor vehicles are formed fromthermoplastic polyolefin containing materials, and other components maybe formed of polypropylene. Several layers of different coatings aretypically utilized to coat these substrates. A primer layer (sometimesreferred to as an adhesion layer) is deposited directly to a surface ofthe polymer, and one or more base coats are deposited overlying theprimer layer. The primer layer improves adhesion of the base coat, andthe base coat provides the desired color and a protective polymericmatrix. A clear coat is often applied overlying the base coat to provideadditional protection and to improve the overall appearance.

Painting is a time and energy intensive process that includes manysteps, where each step requires time and has a cost for the materialsand the labor. Naturally, the more layers that are applied, the greaterthe time and cost required.

Accordingly, it is desirable to develop base coats that do not require aprimer or adhesion coat, methods of coating objects without a primer oradhesion coat, and methods of producing such base coats. In addition, itis desirable to develop base coats that can be directly applied tothermoplastic polyolefin substrates, methods of producing such coatings,and methods of coating such substrates. Furthermore, other desirablefeatures and characteristics of the present embodiment will becomeapparent from the subsequent detailed description and the appendedclaims, taken in conjunction with the accompanying drawing and thisbackground.

BRIEF SUMMARY

Base coats and methods of producing the same are provided. In anexemplary embodiment, a method of producing a base coat includes forminga CPO intermediate and a color intermediate. The CPO intermediateincludes a CPO solvent and a chlorinated polyolefin, where thechlorinated polyolefin is present in the CPO intermediate at from about5 to about 20 weight percent, based on a total weight of the CPOintermediate. The color intermediate includes a color imparting additiveand a color solvent that is different than the CPO solvent. The CPOintermediate and the color intermediate are combined to form the basecoat.

Another method of producing a base coat is provided in a differentembodiment. The method includes forming a CPO intermediate that includesa CPO solvent and a chlorinated polyolefin, where the chlorinatedpolyolefin is present at from about 5 to about 20 weight percent, basedon a total weight of the CPO intermediate. A color intermediate isformed that includes a color imparting additive and a color solvent thatis different than the CPO solvent. The CPO intermediate and the colorintermediate are combined to form a base coat, where the base coatincludes from about 1 to about 3 weight percent chlorinated polyolefinand about 25 weight percent or more solids, based on a total weight ofthe base coat.

A base coat is provided in another embodiment. The base coat includes asolvent comprising acetone, a chlorinated polyolefin at from about 1 toabout 3 weight percent, a coating resin at from about 5 to about 25weight percent, and a color imparting additive at from about 2 to about25 weight percent, all based on a total weight of the base coat. Thebase coat also has solids of from about 25 to about 50 weight percent.

BRIEF DESCRIPTION OF THE DRAWINGS

The present embodiments will hereinafter be described in conjunctionwith the following drawing figures, wherein like numerals denote likeelements, and wherein:

FIG. 1 is a schematic diagram of an embodiment of a mixing and packagingsystem and operation; and

FIGS. 2 and 3 illustrate embodiments of coating a substrate.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the application or uses of the embodimentdescribed. Furthermore, there is no intention to be bound by any theorypresented in the preceding technical field, background, brief summary,or the following detailed description.

Many articles include polymeric substrates, such as automobile parts,helmets, frames, etc. In general, coatings such as paint have pooradhesion to some polymers. Many coatings have poor adhesion tothermoplastic polyolefins and polypropylene in particular, becausethermoplastic polyolefins and polypropylene have low surface energy.Therefore, a primer layer is typically laid down over such substratesprior to a base coat, where the primer helps adhere the base coat. Insome embodiments, the primer layer includes chlorinated polyolefins toaid in adhering to the substrate, and the base coat includes a differentpolymer. Chlorinated polyolefins are relatively soft, so a harderpolymer is included in the base coat to provide superior protection forthe substrate. Chlorinated polyolefins are non-polar and have limitedsolubility in many solvents.

The solvents suitable for chlorinated polyolefins are typically notsuitable for pigments or other color imparting additives and othertypical coating materials, so chlorinated polyolefins are notincorporated into a base coat that includes a color imparting additiveand a coating resin. Because of this, the chlorinated polyolefins andthe base coat polymer and color imparting additive are typically appliedin separate layers (i.e., a primer layer and a base coat layer). It hasbeen discovered that chlorinated polyolefins, color imparting additives,and coating resins can be combined in one base coat without separationor other incompatibility failures if the proper solvents and formulationsteps are utilized. As such, a base coat that includes chlorinatedpolyolefins, color imparting additives, and coating resins can beapplied directly to a polymeric substrate, such as a substrate primarilyincluding thermoplastic polyolefins. In general, the chlorinatedpolyolefins are incorporated into a first CPO solvent in a CPOintermediate, while the color imparting additive is incorporated into asecond color solvent in a color intermediate, where the color solvent isdifferent than the CPO solvent. Once the color imparting additive andchlorinated polyolefin are incorporated into the respective solvents,they can be successfully combined, provided the CPO solvent and thecolor solvent are properly selected.

As used herein, a constituent that “includes” a compound includes thatcompound at from about 1 to about 100 weight percent, based on a totalweight of the constituent, unless otherwise specified. Further, aconstituent that “primarily includes” a compound includes that compoundat from about 50 to about 100 weight percent, based on the total weightof the constituent.

Reference is made to FIG. 1. A CPO intermediate 60 and a colorintermediate 70 are produced, and the CPO intermediate 60 and colorintermediate 70 are combined to produce a base coat 10. The term “basecoat” 10 as used herein, refers to a liquid formulation of a coatingprior to being cured. The base coat 10 is mixed, such as with a mixer14, to combine the various components. The base coat 10 is mixed in avessel 12, where the vessel 12 may be a tank, a pipe, a mixing tube, ora wide variety of shapes that are capable of containing a liquid. In asimilar manner, the mixer 14 may be an agitator, a static mixer, or awide variety of components that are capable of mixing the variouscomponents. Once the components within the vessel 12 are mixed toproduce the base coat 10, the base coat 10 may be packaged fordistribution in one or more containers 16. The container 16 may be acan, a bottle, a tote bin, or almost any container 16 capable of holdinga liquid.

The CPO intermediate 60 includes a chlorinated polyolefin 62 and a CPOsolvent 64. The chlorinated polyolefin 62 may be introduced to the CPOintermediate 60 as a solid powder or as a liquid in an organic solvent.In an exemplary embodiment, the chlorinated polyolefin 62 includeschlorine at from about 15 to about 45 weight percent, based on a totalweight of the chlorinated polyolefin (not including any solvent thechlorinated polyolefin 62 may be dissolved in). In other embodiments,the chlorinated polyolefin 62 includes chlorine at from about 18 toabout 30 weight percent, or from about 20 to about 25 weight percent,all based on the total weight of the chlorinated polyolefin 62.

Several different embodiments of the chlorinated polyolefin 62 arepossible. For example, the chlorinated polyolefin 62 may be anhydridemodified, including maleic anhydride modified. In alternate embodiments,the chlorinated polyolefin 62 is modified to include acrylic moieties,carboxylic moieties, hydroxyl moieties, etc. However, in someembodiments the chlorinated polyolefin 62 is not modified to includeother functional groups.

The chlorinated polyolefin 62 is incorporated into the CPO solvent 64 inthe CPO intermediate 60, and in some embodiments the chlorinatedpolyolefin 62 is dissolved in the CPO solvent 64. However, in alternateembodiments, the chlorinated polyolefin 62 is dispersed into the CPOsolvent 64. In all embodiments, the chlorinated polyolefin 62 forms astable compound in the CPO intermediate 60, where a “stable compound,”as used herein, means a solution or mixture that does not separate,coagulate, or settle within 48 hours when held without mixing at 25degrees Celsius (° C.) and at 1 atmosphere of pressure. In someembodiments, the CPO intermediate 60 is a stable solution, where a“stable solution” is a stable compound that is a solution as opposed toa dispersion or emulsion.

The chlorinated polyolefin is stable in a limited number of solvents, sothe CPO solvent 64 is selected with care. In general, the CPO solvent 64is an organic solvent. In an exemplary embodiment, the CPO solvent 64 isselected from butyl acetate, methyl ethyl ketone, cyclohexane, methylamyl ketone, aromatic compounds having from 6 to 10 carbon atoms(including xylene), and combinations thereof. The chlorinated polyolefin62 is incorporated into the CPO solvent 64 in limited quantities so asto produce a stable CPO intermediate 60. Chlorinated polyolefins 62 atconcentrations of greater than about 20 weight percent are generally notstable in the CPO solvent 64, based on a total weight of the CPOintermediate. In an exemplary embodiment, the CPO intermediate 60includes chlorinated polyolefins 62 at a concentration of from about 5to about 20 weight percent, based on the total weight of the CPOintermediate 60, but in an alternate embodiment the CPO intermediate 60includes chlorinated polyolefin 62 at a concentration of from about 5 toabout 10 weight percent, based on the total weight of the CPOintermediate 60. The CPO intermediate 60 may be mixed or blended toincorporate the chlorinated polyolefin 62 into the CPO solvent 64. Insome embodiments, additional components may also be included in the CPOintermediate 60, such as additives or other materials as discussedbelow.

The color intermediate 70 includes a color imparting additive 72 and acolor solvent 74. The color imparting additive 72 imparts color in thecolor intermediate 70 and in the base coat 10. The color impartingadditive 72 may be a dye, a pigment, another component that imparts adesired color, or a combination thereof, where the color impartingadditive 72 is used to color the base coat 10. Typical color impartingadditives 72 that can be used include filler pigments such as talc,china clay, barytes, carbonates, silicates, and color pigment includingmetallic oxides such as titanium dioxide, zinc oxide and iron oxides ofvarious colors. Other color imparting additives 72 that may be usedinclude, but are not limited to, carbon black and organic coloredpigments and dyes. Exemplary colored pigments and dyes includequinacridones, copper phthalocyanines, perylenes, azo pigments,indanthrone blues, carbazoles such as carbazole violet, isoindolinones,isoindolines, thioindigo reds, and benzimidazolinones. Metallic flakepigments, such as aluminum flakes, mica flakes, pearlescent flakes, or acombination thereof may also be used. The color imparting additive 72may optionally include an effect pigment to impart a special visualeffect such as sparkle, pearlescent, luminescent, and/or metallicappearance or an increased depth of color to the cured coatingcomposition. The color intermediate 70 includes the color impartingadditive 72 at a concentration of from about 3 to about 60 weightpercent, based on a total weight of the color intermediate 70.

The color intermediate 70 also includes the color solvent 74, where thecolor solvent 74 is different than the CPO solvent 64. The color solvent74 is selected to form a stable compound with the color impartingadditive 72, where the color imparting additive 72 is typicallydispersed within the color solvent 74. However, in alternate embodimentsthe color imparting additive 72 is dissolved or emulsified within thecolor solvent 74 such that the color intermediate 70 is a stablecompound. The color solvent 74 may vary with different color impartingadditives 72, where the properties of each color imparting additive 72influence the selection of the color solvent 74. In an exemplaryembodiment, the color solvent 74 is selected from methyl acetate, butylacetate, acetone, heptane, aromatic hydrocarbons, and combinationsthereof. The color intermediate 70 may include other additives orcomponents in various embodiments as well, as discussed below.

The CPO additive 60 and the color additive 70 are combined such that thechlorinated polyolefins 62 are present in the base coat 10 at aconcentration of from about 1 to about 5 weight percent, based on atotal weight of the base coat 10. In an alternate embodiment, thechlorinated polyolefins 62 may be present in the base coat 10 in anamount of about 1 to about 3 weight percent, based on the total weightof the base coat 10. The relative proportions of the CPO additive 60 andthe color additive 70 are determined such that the base coat 10 has thedesired concentration of chlorinated polyolefins 62 and othercomponents.

The base coat 10 also includes a coating resin 22 at from about 5 toabout 25 weight percent in an exemplary embodiment, based on the totalweight of the base coat 10. However, in alternate embodiments the basecoat 10 includes the coating resin 22 at from about 10 to about 20weight percent, or from about 15 to about 20 weight percent, all basedon the total weight of the base coat 10. The coating resin 22 is apolymer, and may be a relatively hard polymer to protect underlyingsubstrates. In an exemplary embodiment, the coating resin 22 is added tothe color intermediate 70 prior to mixing the color intermediate 70 andthe CPO intermediate 60. However, in alternate embodiments (notillustrated), the coating resin 22 may be added to the CPO intermediate60 prior to mixing of the color intermediate 70 and the CPO intermediate60, or the coating resin 22 may be added to the base coat independentlyfrom either the CPO intermediate 60 or the color intermediate 70. Ingeneral, all of the components described herein, other than (1) thechlorinated polyolefin 62, (2) the CPO solvent 64, (3) the colorimparting additive 72, and (4) the color solvent 74 may be introduced tothe base coat 10 either in the CPO intermediate 60, the colorintermediate 70, or independent of either the CPO intermediate or thecolor intermediate 70. FIG. 1 illustrates various components being addedto the color intermediate 70, but this is representative of only one ofmany possible different techniques for adding the various components.

In some embodiments, the coating resin 22 comprises a polymer thatincludes a crosslinkable component, where the crosslinkable componentcrosslinks in the presence of a crosslinking component. The crosslinkingcomponent may be added to the crosslinkable component soon before thebase coat 10 is applied, where the base coat 10 has a “pot life” oncethe crosslinkable and crosslinking components are mixed together. Inthis disclosure, the term “binder” refers to the crosslinkable componentand the crosslinking component, and all other optional film-formingcomponents. The binder generally includes all the film-formingcomponents that contribute to the solid organic portion of the curedcomposition. “Crosslinkable component” means a component that hasfunctional groups appended thereon that are capable of reacting with thecrosslinking component to form a crosslinked network. The crosslinkablecomponent may comprise a compound, oligomer, polymer, or a combinationthereof having at least one functional group reactive with thecrosslinking component. The functional groups in the crosslinkablecomponent can be chosen from hydroxy, amino, hydroxy silane,alkoxysilane, epoxy, carbamate, carboxy, anhydride, acetoacetate, cycliccarbonate, acrylate, azide, thiol, or other functional groups, includingcombinations thereof.

“Crosslinking component” means a component that is capable of reactingwith the functional groups on the crosslinkable component to form acrosslinked network. The crosslinking component can be chosen from thegroup of melamine, amino resin, ketimine resin, polyisocyanate, blockedpolyisocyanate, or other functional groups, including combinationsthereof. The crosslinking component may be added to the base coat 10 ina crosslinking catalyst part soon before application of the base coat 10to a substrate, described more fully below. Generally, from about 0.1 toabout 8 weight percent, based on the weight of the binder, ofcrosslinking catalyst is used, but the amount of crosslinking catalystand the type of crosslinking catalyst depends on the type of coatingresin 22 employed. Several different crosslinking catalysts may be usedin alternate embodiments. Some exemplary catalysts include tin catalystssuch as dibutyl tin dilaurate and dibutyl tin diacetate, tertiaryamines, bismuth, zinc salts, blocked acid catalysts, zirconiumacetylacetonate, or other catalyst. One example of a blocked acidcatalyst is an aromatic sulfonic acid blocked with amino methyl propanolor dimethyl oxazoline. Typically useful aromatic sulfonic acids are paratoluene sulfonic acid, dodecyl benzene sulfonic acid, and decyl benzenesulfonic acid, but other aromatic sulfonic acids may also be utilized inalternate embodiments. One preferred catalyst is dodecyl benzenesulfonic acid blocked with amino methyl propanol.

In alternate embodiments, the coating resin 22 is a non-catalyzed resin.As such, the base coat 10 cures by solvent evaporation, and crosslinkingis limited or not present. In some cases, the non-catalyzed resin doescrosslink on curing, such as by reacting with oxygen in the atmosphere.Exemplary non-catalyzed resins include acrylic resins and alkyd resins,but other non-catalyzed resins may also be utilized.

The coating resin 22 may include a wide variety of polymer types, suchas acrylic resins, urethane resins, polyester resins, alkyd resins,epoxy resins, polyurea polyols, cellulose acetate butyrate resins,melamine resins, or combinations thereof. In some embodiments, thecoating resin 22 is selected from urethane resins, acrylic resins,polyester resins, or combinations thereof. In some embodiments, thecoating resin 22 has a weight average molecular weight of from about15,000 to about 70,000, but other average molecular weights may beutilized in alternate embodiments. Generally, catalysts, color impartingadditives 72 such as pigments, and non-polymeric chemical additives suchas stabilizers described hereinafter are not considered part of thebinder. Non-binder components other than color imparting additivesusually do not amount to more than about 5-15% by weight of the basecoat 10, but other concentration ranges are possible in someembodiments.

The term “solids,” as used herein, refers to the non-volatile portionsof the base coat 10 that remain after curing, and after the solvents(including but not limited to the CPO solvent 64 and the color solvent74) have evaporated. In an exemplary embodiment, the base coat 10 isformulated such that the base coat 10 includes from about 5 to about 50weight percent solids, or from about 10 to about 50 weight percentsolids in an alternate embodiment. In alternate embodiments, the solidsmay be from about 20 to about 50 weight percent, or about 25 to about 50weight percent, or about 25 weight percent or more, based on the totalweight of the base coat 10. The remaining portion of the base coat 10 issolvents or other volatile components that evaporate or dissipate oncuring.

A base coat solvent 26 other than the CPO solvent 64 and the colorsolvent 74 may be added to the base coat 10 independent of the CPOadditive 60 and the color additive 70 in some embodiments. Any solventadded to the CPO additive 60 is included in the CPO solvent 64 in thisdescription, and any solvent added to the color additive 70 is includedin the color solvent 74 in this description. In many embodiments, thebase coat solvent 26 is an organic solvent, and water may be present inthe base coat 10 at a concentration of about 1 weight percent or less,based on the total weight of the base coat 10. Representative base coatsolvents 26 that may optionally be utilized include cyclohexane, methylamyl ketone, and mixtures of dialkyl and trialkyl benzenes with 9 to 10carbons. Other organic solvents that may be utilized include, but arenot limited to: aromatic hydrocarbons, such as aromatic petroleumnaphtha or xylenes; ketones, such as, methyl propyl ketone, methylisobutyl ketone, methyl ethyl ketone or acetone; esters, such as butylacetate or hexyl acetate; glycol ether esters, such as propylene glycolmonomethyl ether acetate; and combinations thereof.

In addition to the above ingredients, the composition may also includeother formulation additives 30 such as toughening agents and flowcontrol agents, for example, such as Resiflow® S (polybutylacrylate),and BYK® 320 and 325 (high molecular weight polyacrylates). Suchadditional formulation additives 30 will, of course, depend on thedesired final properties of the base coat 10, as will be apparent tothose skilled in the art. In addition, the formulation additives 30 mayinclude rheologically active agents, such as Garamite® clay, fumedsilica, urea or other types of sag control agents, and the like. Otherformulation additives 30 that may be added include ultraviolet lightstabilizers, surfactants, fillers, etc. Any one or more of the listedformulation additives 30 or other formulation additives 30 notspecifically mentioned herein may be included in the base coat 10 atfrom about 0 to about 25 weight percent in total, based on the totalweight of the base coat 10.

Reference is made to an exemplary embodiment in FIG. 2, with continuingreference to FIG. 1. The base coat 10 and an optional crosslinkingcatalyst part 40 are combined and applied to a substrate 46 with anapplication device 44. The crosslinking catalyst part 40 is onlyutilized in embodiments where the coating resin 22 of the base coat 10includes a crosslinking component. The crosslinking catalyst part 40 mayalso include solvents, formulation additives, or other components inexemplary embodiments. In the illustrated embodiment, the applicationdevice 44 is a spray gun, but in alternate embodiments the applicationdevice 44 may be brush, a dip tank, a roller, high speed rotationalelectrostatic bells, or other devices capable of applying the base coat10 to the substrate 46. In an exemplary embodiment, the base coat 10directly contacts the substrate 46, such that there is no primer layerbetween the base coat 10 and the substrate 46.

The substrate 46 primarily includes a polymer in an exemplaryembodiment, where the polymer may include a polyolefin, and in someembodiments the substrate 46 primarily includes a polyolefin.Polypropylene is one example of a polyolefin, but other polyolefins areutilized in alternate embodiments. In some embodiments, the substrate 46may include acrylonitrile butadiene styrenes, cellulose acetatebutyrates, carbon nitrides, ethylene propylenes, melamine formaldehydes,polyamides, polyamides, polycarbonates, polyethyelenes, polybutyleneterephthalates, polyethylene terephthalates, polythiophenes, poly(methylmethacrylates), polyoxymethylenes, polypropylenes, poly(phenyleneoxides), photoluminescence polymers, polyvinyl chlorides, styreneacrylonitriles, nylons, benzimidazobenzophenanthrolines, polyesters andreinforced polyesters, polyurethanes and thermoplastic polyurethanes,and other polymers. The substrate 46 may be a component of an automobilein some embodiments, but the substrate 46 may be another article inalternate embodiments.

The base coat 10 is cured after being applied to the substrate toproduce the cured coating layer 50. In an exemplary embodiment asdescribed above, the base coat 10, prior to curing, is applied directlyto a face of the substrate 46, so the cured coating layer 50 (aftercuring) directly contacts the substrate 46. The cured coating layer 50includes the coating resin 22, which is crosslinked on curing in someembodiments, as well as the color imparting additive 72 and thechlorinated polyolefin 62. The solvent, including the CPO solvent 64,the color solvent 74, and the optional base coat solvent 26, may beremoved during the curing process, such as by evaporation. The curedcoating layer 50 may be from about 0.2 to about 3.0 mils thick in anexemplary embodiment, but in alternate embodiments the cured coatinglayer 50 may be from about 0.5 to about 2.5 mils thick, or from about0.5 to about 1.5 mils thick.

A clearcoat 52 may optionally be applied overlying the cured coatinglayer 50, as illustrated in an exemplary embodiment in FIG. 3 withcontinuing reference to FIGS. 1 and 2. The clearcoat 52 is then cured toform a cured clearcoat 54. A wide variety of clearcoats 52 may beemployed, and the clearcoat 52 is typically selected based on the typeof coating resin 22 within the base coat 10. The clearcoat 52 may beapplied before or after the base coat 10 is cured in variousembodiments. For example, the base coat 10 may be coated with theclearcoat 52 or with a second layer of the base coat 10 or with othercoatings while wet, or after flash drying of the base coat 10 but beforecomplete curing, or after curing. The cured clearcoat 54 may be fromabout 0.5 to about 4.0 mils thick in an exemplary embodiment, but inalternate embodiments the cured clearcoat 54 may be about 1.0 to about3.0 mils thick, or from about 1.5 to about 2.5 mils thick.

The cured coating layer 50 and/or the cured clearcoat 54 may be cured bythe passage of time, where the solvent is allowed to evaporate and theoptional crosslinkable component and the optional crosslinking componentare allowed to react and produce a crosslinked network. However, inalternate embodiments the cured coating layer 50 and/or the curedclearcoat 54 may be cured by baking, such as at a temperature of fromabout 25 degrees Celsius (° C.) to about 120° C., or by infraredirradiation, or by other techniques. The curing process for the curedcoating layer 50 may be independent from the curing process for thecured clearcoat 54 in some embodiments, but in other embodiments thecured coating layer 50 and the cured clearcoat 54 are curedsimultaneously.

The cured clearcoat layer 54 provides a durable, high gloss appearanceto the substrate 46, and protects the cured coating layer 50. In anexemplary embodiment, the clearcoat 52 is a solvent borne materialincluding a film forming binder, and the clearcoat 52 may include acrosslinking agent. As such, a crosslinkable component and acrosslinking component of the clearcoat 52 may be combined shortlybefore application. The term “solvent borne” means the liquid carrier ofa composition includes water at about 1 percent or less by weight, basedon the total amount of liquid carrier. The film forming binder of theclearcoat 52 is referred to as the clearcoat binder in this description.In an exemplary embodiment, the clearcoat binder is about 40-70 weightpercent of the clearcoat 52, and a volatile organic solvent is about30-60 weight percent of the clearcoat composition, where the organicsolvent typically volatilizes at about 35 degrees centigrade (° C.) toabout 100° C. or more. The clearcoat 52 may also include otherformulation additives 30 as discussed above, which may be the same ordifferent than in the base coat 10. The clearcoat binder may be insolution or in a dispersion in the organic solvent. Alternateembodiments of the clearcoat 52 are also possible.

Expiremental

Table 1, below, includes experimental data developed in efforts toprepare a basecoat that includes chlorinated polyolefins 62 (CPO). Thesolvent testing system utilized included: (a) combining 31 grams (g) ofa CPO composition with 69 g of a test CPO solvent 64, where the test CPOsolvent 64 is named in the second Column of Table 1; (b) determining ifthe resulting CPO intermediate 60 formed a stable mixture; (c) If theCPO intermediate 60 formed a stable mixture, 100 g of the stable CPOintermediate 60 was combined with 150 g of a color intermediate 70 toform a test base coat 10, where the color intermediate 70 included ablack color imparting additive 72 and a color solvent 74; and (d)determining if the resulting test base coat 10 formed a stable mixture.The test base coat 10 was observed for stability after 1 hour, and againafter 24 hours, where stability after 24 hours was used to indicate thetest base coat 10 was a stable product suitable for the marketplace.NOTE: The test CPO solvent amount was 69 g in all rows, the CPOcomposition described above was 31 g in all rows, and the productstability columns indicate the stability after the formation of the testbase coat 10 in all rows, if applicable.

The color solvent 74 in the color intermediate 70 was 56 weight percentmethyl/butyl acetates; 10 weight percent methyl amyl ketone; 14 weightpercent acetone; 15 weight percent trimethyl benzene isomers; and 5weight percent heptane, where the weight percents are based on a totalweight of the color solvent 74. The CPO composition named above included31 weight percent of a chlorinated polyolefin 62 dissolved in an organicsolvent, where the organic solvent included 34.2 weight percent methylamyl ketone, 27.0 weight percent cyclohexane, 0.3 weight percent of aflow additive, and 7.5 weight percent butyl acetate, where all weightpercents are based on a total weight of the CPO composition.

TABLE 1 Status after mix of test Solvent CPO solvent Test base Test basefunctional and CPO coat stability coat stability family Test CPO solventcomposition Notes after 1 hour after 24 hours Ketone Acetone Fail Largeseeds, N/A N/A chunks Ketone Methyl amyl Pass Clean & clear Pass Passketone Ester N-butyl acetate Pass Clean & clear Pass Pass EsterTert-butyl acetate Pass Clean & clear Pass Pass Ester Ethyl 3- MarginalClean but Large seeds, N/A ethoxypropionate milky chunks Ester Ethylhexyl Pass Clean & clear Pass Pass acetate Alcohol Isopropyl alcoholFail Large seeds, N/A N/A chunks Alcohol Mixed dibasic fail Large seeds,N/A N/A ester (succinic, chunks glutaric, adipic di-methyl ester)Alcohol Ethylene glycol Marginal Clean, Large seeds, N/A monohexyl etherslightly cloudy chunks Ether Ethylene glycol Pass Clean & clear Largeseeds, N/A acetate monobutyl ether chunks acetate Aliphatic Naphtha PassClean & clear Pass Pass hydro- (refinery) carbon Aliphatic Mineralspirits Pass Clean & clear Large seeds, N/A hydro- (45-205° C. 0 chunkscarbon Aromatic Trimethyl Pass Clean & clear Pass Pass hydro- benzene(isomer carbon mixture)

The testing indicates the black base coat 10, which has an establishedsolvent system, may be combined with the chlorinated polyolefin 62 whenthe chlorinated polyolefin 62 is solubilized in the test CPO solvent 64,but only when certain select test CPO solvents 64 are used. Many testCPO solvents 64 failed the compatibility test with the solvents in theblack basecoat, so only specific, selected solvents may be used with thechlorinated polyolefin 62.

Further testing has shown that the total solids may approach a value ofabout 50 weight percent or more, based on a total weight of the basecoat 10. Using the solvent system described herein, a base coat 10 witha black color imparting additive 72 was produced, where the black basecoat 10 had 38.12 weight percent non-volatiles (i.e., solids). Thisblack base coat 10 was stable and tested at 100% adhesion when appliedto a test polymeric substrate 46. A white base coat 10 with a whitecolor imparting additive 72 was produced, and the white base coat 10 had48.14 weight percent non-volatiles (i.e., solids). This white base coat10 was also stable and tested at 100% adhesion when applied to a testpolymeric substrate 46. The weight percents in this paragraph are basedon a total weight of the base coat 10 tested. This demonstrates that thesolvent system described herein may be utilized with solids levelsapproaching 50 weight percent or more, based on the total weight of thebase coat 10. In particular, solids levels of at least 38 weight percentmay be used, and solids levels of at least 48 weight percent may be usedwith select color imparting additives 70. Further increases in thesolids level may also be possible while producing stable base coats 10.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or exemplary embodiments are only examples, and arenot intended to limit the scope, applicability, or configuration of theapplication in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing one or more embodiments, it being understood that variouschanges may be made in the function and arrangement of elementsdescribed in an exemplary embodiment without departing from the scope,as set forth in the appended claims.

What is claimed is:
 1. A method of producing a base coat, the methodcomprising the steps of: forming a CPO intermediate comprising a CPOsolvent and a chlorinated polyolefin, wherein the CPO intermediatecomprises from about 5 to about 20 weight percent of the chlorinatedpolyolefin, based on a total weight of the CPO intermediate; forming acolor intermediate comprising a color imparting additive and a colorsolvent, wherein the color solvent is different than the CPO solvent;and combining the CPO intermediate with the color intermediate to formthe base coat.
 2. The method of claim 1 wherein forming the CPOintermediate comprises forming the CPO intermediate with from about 5 toabout 10 weight percent of the chlorinated polyolefin.
 3. The method ofclaim 1 wherein: the CPO solvent comprises one or more of methyl amylketone and butyl acetate; and the color solvent comprises acetone. 4.The method of claim 1 wherein: the base coat comprises from about 1 toabout 5 weight percent of the chlorinated polyolefin, based on a totalweight of the base coat; and the base coat comprises solids at fromabout 5 to about 50 weight percent, based on the total weight of thebase coat.
 5. The method of claim 1 wherein: the base coat furthercomprises a coating resin, and wherein the color intermediate comprisesthe coating resin.
 6. The method of claim 5 wherein: the coating resincomprises a crosslinkable component, the method further comprising:forming a crosslinking catalyst part, wherein the crosslinking catalystpart comprises a crosslinking component configured to crosslink thecrosslinkable component of the coating resin; and combining thecrosslinking catalyst part with the base coat.
 7. The method of claim 5wherein: the coating resin is selected from the group consisting of aurethane resin, an acrylic resin, a polyester resin, and combinationsthereof.
 8. The method of claim 1 wherein: the CPO intermediate whereinthe CPO solvent comprises methyl amyl ketone.
 9. The method of claim 1wherein: the CPO intermediate comprises butyl acetate.
 10. The method ofclaim 1 wherein: the base coat comprises solids at from about 20 toabout 50 weight percent, based on a total weight of the base coat. 11.The method of claim 1 wherein: forming the CPO intermediate comprisesforming the CPO intermediate wherein the chlorinated polyolefincomprises maleic anhydride modified chlorinated polyolefins.
 12. Themethod of claim 1 wherein: forming the CPO intermediate comprisesdissolving the chlorinated polyolefin in the CPO solvent.
 13. The methodof claim 1 wherein: forming the CPO intermediate comprises forming theCPO intermediate wherein the chlorinated polyolefin comprises chlorineat from at from about 15 to about 45 weight percent based on a totalweight of the chlorinated polyolefin.
 14. A method of producing a basecoat, the method comprising the steps of: forming a CPO intermediatecomprising a CPO solvent and a chlorinated polyolefin, wherein thechlorinated polyolefin comprises from about 5 to about 20 weight percentof the CPO intermediate, based on a total weight of the CPOintermediate; forming a color intermediate comprising a color impartingadditive and a color solvent, wherein the color solvent is differentthan the CPO solvent; and combining the CPO intermediate with the colorintermediate to form the base coat, wherein the base coat includes thechlorinated polyolefin at from about 1 to about 3 weight percent, basedon a total weight of the base coat, and wherein the base coat comprisessolids at about 25 weight percent or more, based on the total weight ofthe base coat.
 15. The method of claim 14, wherein: the base coatcomprises the solids at from about 25 to about 50 weight percent, basedon the total weight of the base coat.
 16. The method of claim 14wherein: the CPO solvent comprises one or more of butyl acetate andmethyl amyl ketone; and the color solvent comprises acetone.
 17. Themethod of claim 14 further comprising: adding a coating resin to thebase coat, wherein the coating resin comprises a crosslinkablecomponent; forming a crosslinking catalyst part, wherein thecrosslinking catalyst part comprises a crosslinking component configuredto crosslink with the crosslinkable component of the coating resin; andcombining the crosslinking catalyst part with the base coat.
 18. Themethod of claim 14 wherein: the CPO solvent comprises butyl acetate. 19.The method of claim 14 wherein: the CPO solvent comprises methyl amylketone.
 20. A base coat comprising: a chlorinated polyolefin at fromabout 1 to about 3 weight percent, based on a total weight of the basecoat; a coating resin at from about 5 to about 25 weight percent, basedon the total weight of the base coat; a solvent, wherein the solventcomprises acetone; a color imparting additive at from about 2 to about25 weight percent, based on the total weight of the base coat; andwherein the base coat comprises solids at from about 25 to about 50weight percent, based on the total weight of the base coat.